Coreless rotating electrical machine for being operated under load exceeding rating, driving method thereof, and driving system including thereof

ABSTRACT

A coreless rotating electrical machine for being operated under load exceeding rated load, driving method thereof, driving system including thereof; coreless rotating electrical machine for being operated under load exceeding rated load, driving method thereof, driving system including thereof, in which air space including air gap is formed by stator consisting of lid-type mount which fixes end face of energizable coreless cylindrical coil and rotor consisting of cylindrical mount or cup-type mount opposingly and rotatably positioned to lid-type mount with plurality of magnets equipped on inner surface of cylindrical or cup-type mount, wherein when load exceeds the rating, operation is enabled by adjusting supply amount of refrigerant liquid so the temperature of cylindrical coil does not exceed allowable maximum temperature at rated operation; refrigerant liquid supplied to air space including air gap to allow cylindrical coil to vaporize refrigerant liquid to cool by latent heat of vaporization of refrigerant liquid.

TECHNICAL FIELD

The present invention relates to a coreless rotating electrical machine for being operated under a load exceeding a rating, a driving method thereof, and a driving system including thereof.

More specifically, the present invention relates to a coreless rotating electrical machine, a driving method thereof, and a driving system including thereof, in which an air space including an air gap is formed by a stator consisting of a lid-type mount which fixes an end face of an energizable coreless cylindrical coil and a rotor consisting of a cylindrical or cup-type mount opposingly and rotatably positioned with respect to the lid-type mount with a plurality of magnets equipped on an inner surface of the cylindrical mount, and when it is to be operated under the load exceeding the rating, such operation is enabled by adjusting supply amount of the refrigerant liquid so that the temperature of the cylindrical coil does not exceed the allowable maximum temperature at a rated operation, in which the refrigerant liquid is supplied to the air space to allow the cylindrical coil, which generates heat, to vaporize the refrigerant liquid so as to cool itself by latent heat of vaporization of the refrigerant liquid.

BACKGROUND ART

An electric motor and an electric generator are both a rotating electrical machine having a same structure. Descriptions are made for the rotating electrical machine using the electric motor which converts electrical energy to kinetic energy. The electric motor outputs electromagnetic power generated by an interaction of a magnetic field and electricity. There are various methods of classification, but generally they are classified as a DC motor with brush or a brushless motor, wherein the former uses a magnet as a stator, coil as a rotor, and conversely, the latter uses a coil as a stator, a magnet as a rotor, and each of them is what outputs electromagnetic power to outside from the rotor. On the other hand, the electric is also classified as a winding-field type or a permanent-magnet type depending on a difference in generating the magnetic field, and is also classified based on whether a coil is with or without a core. According to the classification described in the above, the subject of the present invention is a permanent-magnet field type coreless brushless electric motor.

The present invention relates to a coreless brushless motor consisting of a permanent-magnet field type coreless cylindrical coil. The coreless cylindrical coil of a stator is either made with a laminate of electrically conductive metal sheets having linear parts covered with insulating layers, or made with a linear conductor covered with an insulating layer.

The electric motor may momentarily exceed a rated current at start-up, but it is not assumed to be continuously operated under a condition exceeding a rating. When the electric motor is continuously operated under an overload condition, that is, continuously operated above the rating, the cylindrical coil of the electric motor generates heat more than assumed by electric current applied.

Though it depends on structures and functions of the electric motor, when overload tests are performed under each of conditions exceeding the rating, using a coreless motor (CP50) manufactured as a test motor related to the present invention, without activating a controlling part of a refrigerant liquid supply, an allowable maximum temperature of the cylindrical coil, which is 130° C., is exceeded in only a few tens of seconds, as described in the followings. The worst state which may be easily assumed to be caused from the above is that the cylindrical coil burns out and be destructed. Even if the cylindrical coil does not result in destruction, it is no longer possible to expect a normal long-time operation of the coreless motor in the context of performance. It has been well-known without mentioning, and it is merely a commonly used means to add a cooling function to the electric motor in order to prevent a decrease in performance of the electric motor accompanied with heat generation of the cylindrical coil and/or heating of the magnet.

In spite of existence and non-existence of such cooling function, a maximum temperature limit for a coil and/or magnets during a normal operation of an electric motor is shown as a rating from a manufacturer (page 41 of Non-Patent Document 1). The rating is a unique standard guaranteed by the manufacturer, and is described in catalogs and/or specifications, it means that, for example, the maximum output from the motor at a predetermined voltage, with the motor exerting a good property, becomes a rated output, a rotating speed when operated under the rated output is a rated rotating speed, a torque T at such time is a rated torque, and a current at such time is a rated current. When usage is not specified, a continuous rating which allows an operation for an indefinite period of time is provided as the rating. As other ratings, there are a short-time rating in which an operational period is limited and/or an intermittent-service rating in which an operation is repeatedly made on and off periodically etc.

The present invention relates to a coreless motor for being operated under a load exceeding a rating, which is developed based on an idea of enabling a constant operation under overload. The term “rating” described herein refers to, for example, a rating when the coreless motor is operated at a predetermined voltage under a rated torque or a rated output.

In this regard, the coreless motor (CP50) manufactured as a test motor is a so-called electric motor. While details will be described in the followings, conditions of the rating described here are that, a continuous operation is performed with the refrigerant supply amount being zero, and without activating the controlling part of the refrigerant supply, and also that the temperature of the cylindrical coil does not exceed the allowable maximum temperature which is 130° C., wherein the rated torque is T₀=0.28 Nm, the rated current is I₀=9.7 Arms, the rated rotating speed is n₀=6537 rpm and the rated output is P₀=191.67 W (FIG. 11).

Next, it has been well-known to add a cooling function to an electric motor in order to prevent decrease in performance of the electric motor accompanied with heat generation of a cylindrical coil and/or heating of a magnet. This is appreciated from the following conventional techniques.

Patent Document 1 (PCT Japanese Publication: JP2012-523817A) describes as that, a diffusive material is disposed around coils, which absorbs a liquid coolant having a boiling point below a working temperature of the coils to make the coil wet so that the coils are cooled by heat of vaporization of the boiled liquid coolant.

Patent Document 2 (Japanese Laid-Open Patent Publication H10-336968A) describes a system, including a radiator, configured such that a centrifugal pump action of a rotor and height difference are used for refrigerant circulation of a gas-liquid two-phase so that inside of a rotating electrical appliance for vehicle is cooled.

Patent Document 3 (Japanese Laid-Open Patent Publication 2006-14522A) describes storing a refrigerant, which temperature of a boiling point is lower than an allowable maximum temperature, in an electric generator, and efficiently cooling the electric generator while alternatively repeating vaporizing of the refrigerant and devolatilizing of the refrigerant inside the electric generator during operation of the electric generator.

Patent Document 4 (Japanese Laid-Open Patent Publication 2006-158105A) describes evaporating a coolant in a liquid phase in an auto-circulating path including a reservoir tank of the coolant with heat generated from a rotor to allow for efficient cooling with the evaporated coolant.

Patent Document 5 (Japanese Laid-Open Patent Publication 2009-118693A) describes a method for cooling a rotor with latent heat of vaporization, in which, in a rotor cooling apparatus, a refrigerant is continuously supplied little by little toward a cooling wall surface of the rotor such that the refrigerant may not be located eccentrically on the wall.

Patent Document 6 (Japanese Laid-Open Patent Publication 2015-95961A) describes a cooling structure of a motor in which, in a sealed case of the motor, a refrigerant included in the case is vaporized by heat of a coil of a stator, devolatilized in a heat releasing part and circulated in the sealed case. This cooling structure is common with what are described in Patent Documents 3 and/or 4.

Patent Document 7 (Japanese Laid-Open Patent Publication 2009-118686A) describes a cooling structure of a rotating electrical appliance in which a refrigerant distribution channel for cooling magnets and that for cooling a coil is respectively provided, and the channels are arranged with a switchable means.

Patent Document 8 (Japanese Laid-Open Patent Publication 2014-17968A) describes a cooling system of a rotating electrical appliance mounted on a hybrid vehicle. The rotating electrical appliance comprises a coil part which winds around a stator core formed by laminating a plurality of electromagnetic steel plates. The cooling system of the rotating electrical apparatus having an iron core disclosed therein is configured such that, when a temperature of windings of the coil part exceeds 180° C. for more than 10 times, an insulated covering around the windings of the coil part evaporates or vaporizes and be dissipated to result in a decrease in performance for withstanding discharge pressure, and thus, a controlling part is equipped for adjusting supply amount of a refrigerant to form a state where the refrigerant is adhered around the windings of a specific portion so as to prevent such decrease in performance.

Patent Document 9 (Japanese Laid-Open Patent Publication H06-217496A) describes an electric generator in which an evaporative condensation room is provided inside a rotor of the electric generator, a cooling liquid is fed with a jet stream from outside in an axial direction, and an impeller for waste liquid is provided in a liquid room connected with a cooling liquid room which uses centrifugal force to deflect the cooling liquid to the evaporative condensation room side to make it flow.

Patent Document 10 (Japanese Laid-Open Patent Publication H05-308752A) describes a radiating structure of a motor placed in a housing where a rotor and an annular stator surrounding the rotor are in an air tight state, in which a pipe in communication with an annular cavity in the housing to which a working fluid is included, and a Whitworth having a capillary action are arranged.

Patent Document 11 (Japanese Laid-Open Patent Publication H08-130856A) describes a cooling circuit, in which, in a driving device motor for electric vehicle consisting of a coil winded on a cylindrical core, oil is dropped on a coil end from a cooling oil pump via a cooling oil injection part.

CITATION LIST Patent Documents

Patent Document 1: PCT Japanese Publication: JP2012-523817A

Patent Document 2: Japanese Laid-Open Patent Publication H10-336968A

Patent Document 3: Japanese Laid-Open Patent Publication 2006-14522A

Patent Document 4: Japanese Laid-Open Patent Publication 2006-158105A

Patent Document 5: Japanese Laid-Open Patent Publication 2009-118693A

Patent Document 6: Japanese Laid-Open Patent Publication 2015-95961A

Patent Document 7: Japanese Laid-Open Patent Publication 2009-118686A

Patent Document 8: Japanese Laid-Open Patent Publication 2014-179681A

Patent Document 9: Japanese Laid-Open Patent Publication H06-217496A

Patent Document 10: Japanese Laid-Open Patent Publication H05-308752A

Patent Document 11: Japanese Laid-Open Patent Publication H08-130856A

Non-Patent Documents

Non-Patent Document 1: “Best Colored Illustration, All of Current Motor Technology”, Edited by Kan Akatsu, Natsume Publishing Planning Co., Ltd. (Published on Jul. 20, 2013)

SUMMARY OF INVENTION Technical Problem

A technical problem inherent in an electric motor, which is rotated by electromagnetic action of components such as a stator and a rotor, is heat generation action of a coil which is an armature equipped, on the stator. Performance and/or size of the electric motor are generally represented by output of the electric motor. The output P₀ is represented by the product of rotating speed n (rpm) and torque T (N·m). Provided that input power of the electric motor is P₁(W), a difference between the input power P₁ and the output P₀ is converted to heat energy as heat loss P_(L) and discharged to the environment. This is the heat generation action of the armature coil, and is the technical problem of the electric motor which is difficult to be avoided. For example, not applied only to a coreless motor, it has been a well-known matter for those skilled in the art that, when the electric motor is continued to be operated under the load exceeding the rating, an allowable maximum temperature of the armature coil is exceeded in a short time due to such heat generation action, resulting in burnout and destruction. There is also a problem inherent in the electric motor that the heat generation action of the armature coil raises a resistance value of the armature coil, and evokes output fluctuation of the electric motor, and thus, it is also an ultimate technical problem of the electric motor to completely control the temperature of the armature coil in a certain range so as to minimize the output fluctuation.

The problem may be solved by finding a way to control the temperature of the armature coil. Various proposals as described in the above have been made to address the problem but have not led to a fundamental solution for the ultimate problem of completely controlling the temperature of the armature coil in the certain range.

Solution to Problem

However, the inventors have challenged to develop an electric motor based on the idea of enabling the constant operation under overload, and realized a coreless rotating electrical machine for being operated under a load exceeding a rating, a method for driving thereof, and a driving system including thereof, and came up with solving the technical problem. This can be confirmed from driving tests using a coreless motor (CP50) manufactured based on one embodiment of the present invention.

The voltage of the coreless motor (CP50) is set to 24 V, and measured the torque. This is the rated torque T₀=0.28 Nm. The inventors of the present invention have confirmed that a long time operation of the coreless motor (CP50) is possible by completely controlling the heat generation of the cylindrical coil, which is the armature coil, with a load exceeding the rated torque T₀ being continuously applied to the coreless motor (CP50).

The first aspect of the present invention is a coreless rotating electrical machine 10 for being operated under a load exceeding a rating, shown in a cross sectional schematic diagram of FIG. 1 and a broken perspective diagram of FIG. 2.

It is the coreless rotating electrical machine 10 in which an air space 40 including an air gap is formed by a stator 2 consisting of a lid-type mount 200 which fixes an end face 101 of an energizable coreless cylindrical coil 100 and a rotor 3 consisting of a cylindrical mount 300 opposingly and rotatably positioned with respect to the lid-type mount 200 with a plurality of magnets 4 equipped on an inner surface 310 of the cylindrical mount 300; a channel 8 for supplying a refrigerant liquid 80 to the air space 40 is provided on the stator 2; and a controlling part 20 related to the stator 2 and a driving part 30 related to the rotor 3 are equipped therewith.

It can also be equipped, on the stator 2, with a refrigerant liquid container 81 which is in communication with the channel 8, and a circulating means 82 which communicates between the refrigerant liquid container 81 and the air space 40.

As apparent from the first aspect of the present invention, the coreless rotating electrical machine 10 is characterized in that, the driving part 30 is activated, and when it is to be operated under the load exceeding the rating, such operation is enabled by activating the controlling part 20 to adjust supply amount of the refrigerant liquid 80 so that the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M) at a rated operation, in which the refrigerant liquid 80 is supplied to the air space 40 to allow the cylindrical coil 100, which generates heat, to vaporize the refrigerant liquid 80 so as to cool itself by latent heat of vaporization of the refrigerant liquid 80.

As one embodiment of the present invention, it is more preferable that, when the cureless rotating electrical machine 10 is operated under the load exceeding the rating, an operation of activating the controlling part 20 to adjust supply amount of the refrigerant liquid 80 so that the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M), and an operation to stop supplying of the refrigerant liquid 80 to the air space 40 so that the temperature of the cylindrical coil 100 at least does not fall below the minimum temperature t_(N) where the refrigerant liquid 80 vaporizes by the above operation are repeated so as to maintain the temperature of the cylindrical coil 100 in a range between the allowable maximum temperature t_(M) and the minimum temperature t_(N).

As another embodiment of the present invention, as shown in a schematic diagram of FIG. 5, the controlling part 20 may comprise a coil temperature detecting sensor 21 for detecting a temperature of the cylindrical coil 100, a pump 22 for supplying the refrigerant liquid 80 to the air space 40 in coordination with the coil temperature detecting sensor 21, and a controller 23 for adjusting supply amount of the refrigerant liquid 80 with on/off command to the pump 22.

As a further embodiment of the present invention, as shown in a schematic diagram of FIG. 6, the controlling part 20 may comprise a coil temperature detecting sensor 21 for detecting a temperature of the cylindrical coil 100, an electromagnetic valve 24 for supplying the refrigerant liquid 80 to the air space 40 from the refrigerant liquid container 81 arranged at a position higher than the cylindrical coil 100, in coordination with the coil temperature detecting sensor 21, and a controller 23 for adjusting supply amount of the refrigerant liquid 80 with open/close command to the electromagnetic valve 24.

As another embodiment of the present invention, as shown in FIG. 5 or FIG. 6, the controlling part 20 may be configured such that the refrigerant liquid 80 in a gas phase 800 is collected in a liquid phase 80 into the refrigerant liquid container 81 by a circulating means 82.

As a further embodiment of the present invention, as shown in FIGS. 1 and 2, the coreless rotating electrical machine 10 may be configured such that a drive shaft 1000 is equipped as being fixed to a center part 340 of the cylindrical mount 300, and rotatably coupled to a center part 240 of the lid-type mount 200.

The second aspect of the present invention is a coreless rotating electrical machine 10 for being operated under a load exceeding a rating shown in a cross sectional schematic diagram of FIG. 3 and a broken perspective diagram of FIG. 4.

It forms a first air space 40 including an air gap by a stator 2 consisting of a lid-type mount 200 which fixes one of end faces 101 of an energizable coreless cylindrical coil 100, and a rotor 3 consisting of a cup-type mount 400 opposingly and rotatably positioned with respect to the lid-type mount 200, wherein the cup-type mount 400 included in the rotor 3 has a bottom part 410 open at one end and closed at the other end, to which concentric inner yoke 420 and outer yoke 430 are integrated, and the rotor is equipped with a plurality of magnets 4 with intervals with respect to each other in a circumferential direction on an outer surface 422 of the inner yoke 420 and/or an inner surface 431 of the outer yoke 430, and provided with slits 423, each of which passing through the inner yoke 420, at positions of the inner yoke 420 corresponding to each of the intervals 41.

Further, it is the coreless rotating electrical machine 10 for being operated under the load exceeding the rating, in which the cylindrical coil 100 is arranged in a first air space 40 as suspended such that the other end face 102 of the cylindrical coil 100 leaves a clearance 411 between the bottom 410 of the cup-type mount 400; a second air space 50 is formed between one of end faces 401 of the cup-type mount 400 and the lid-type mount 200 at an inner periphery side 110 of the cylindrical coil 100; a third air space 60 is formed at an outer periphery side 120 of the cylindrical coil 100; a channel 8 for supplying a refrigerant liquid 80 to the first air space 40 is provided on the stator 2; and a controlling part 20 related to the stator 2, and a driving part 30 related to the rotor 3 are equipped therewith.

It also can be equipped, on the stator 2, with a refrigerant liquid container 81 which is in communication with a channel 8, and further equipped with a circulating means 82 which communicates between the refrigerant liquid container 81 and the first air space 40.

As apparent from the second aspect of the present invention, the coreless rotating electrical machine 10 is characterized in that, the driving part 30 is activated, and when it is to be operated under the load exceeding the rating, such operation is enabled by activating the controlling part 20 to adjust supply amount of the refrigerant liquid 80 so that the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M) at a rated operation, in which the refrigerant liquid 80 is supplied to inside 421 of the inner yoke 420 of the first air space 40 to allow the cylindrical coil 100, which generates heat, to vaporize the refrigerant liquid 80 fed be cylindrical coil 100 via the slits 423 so as to cool itself by latent heat of vaporization of the refrigerant liquid 80.

As one embodiment of the present invention, it is more preferable that, when the coreless rotating electrical machine 10 is operated under the load exceeding the rating, an operation of activating the controlling part 20 to adjust supply amount of the refrigerant liquid 80 so that the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M), and an operation of stop supplying of the refrigerant liquid 80 to the air space 40 so that the temperature of cylindrical coil 100 does not fall below the allowable minimum temperature t_(N) where the refrigerant liquid 80 vaporizes by the above operation are repeated so as to maintain the temperature of the cylindrical coil 100 in a range between the allowable maximum temperature t_(M) and the allowable minimum temperature t_(N).

As another embodiment of the present invention, as shown in a schematic diagram of FIG. 5, the controlling part 20 may comprise a coil temperature detecting sensor 21 for detecting a temperature of the cylindrical coil 100, a pump 22 for supplying the refrigerant liquid 80 to inside 421 of the inner yoke 420 of the first air space 40 in coordination with the coil temperature detecting sensor 21, and a controller 23 for adjusting the supply amount of the refrigerant liquid 80 with on/off command to the pump 22.

As a further embodiment of the present invention, as shown in a schematic diagram of FIG. 6, the controlling part 20 may comprise a coil temperature detecting sensor 21 for detecting a temperature f the cylindrical coil 100, an electromagnetic valve 24 for supplying the refrigerant liquid 80 to inside 421 of the inner yoke 420 of the first air space 40 from the refrigerant liquid container 81 arranged at a position higher than the cylindrical coil 100, in coordination with the coil temperature detecting sensor 21, and a controller 23 for adjusting supply amount of the refrigerant liquid 80 with open/close command to the electromagnetic valve 24.

As another embodiment of the present invention, as shown in FIG. 5 of FIG. 6, the controlling part 20 may be configured such that the refrigerant liquid 80 in a gas phase 800 is collected in a liquid phase 80 into the refrigerant liquid container 81 by a circulating means 82.

As a further embodiment of the present invention, as shown in FIGS. 3 and 4, the coreless rotating electrical machine 10 may be configured such that a drive shaft 1000 is equipped as being fixed to a center part 340 of the cup-type mount 400, and rotatably coupled to a center part 240 of the lid-type mount 200.

As one embodiment in the first and second aspects of the present invention, it is preferred that the cylindrical coil 100 is made from what formed to a cylindrical form by either of a laminate of electrically conductive metal sheets having linear parts being spaced in an axial direction covered with insulating layers, or a linear conductor covered with an insulating layer.

As another embodiment in the first and second aspects of the present invention, it is preferred that the refrigerant liquid 80 is any of water, ethanol, ammonia, liquid nitrogen, liquid helium or fluorinated liquid.

The third aspect of the present invention is a driving method of a coreless rotating electrical machine 10 for being operated under a load exceeding a rating, shown in FIG. 1 and FIG. 2.

It is the driving method of the coreless rotating electrical machine 10 for being operated under a load exceeding a rating, in which an air space 40 including an air gap is formed by a stator 2 consisting of a lid-type mount 200 which fixes an end face 101 of an energizable coreless cylindrical coil 100 and a rotor 3 consisting of a cylindrical mount 300 opposingly and rotatably positioned with respect to the lid-type mount 200 with a plurality of magnets 4 equipped on an inner surface 310 of the cylindrical mount 300; a channel 8 for supplying a refrigerant liquid 80 to the air space 40 is provided on the stator 2; and a controlling part 20 related to the stator 2 and a driving part 30 related to the rotor 3 are equipped therewith.

Further, in the driving method of the present invention, the coreless rotating electrical machine 10 can also be equipped, on the stator 2, with a refrigerant liquid container 81 which is in communication with the channel 8, and a circulating means 82 which communicates between the refrigerant liquid container 81 and the air space 40.

As apparent from the third aspect of the present invention, the method is characterized in that it comprises: a step of activating the driving part 30 and operating the coreless rotating electrical machine 10 under the load exceeding the rating; a step of activating the controlling part 20 to supply the refrigerant liquid 80 to the air space 40; a step of allowing the cylindrical coil 100, which generates heat, to vaporize the refrigerant liquid 80 so as to cool itself by latent heat of vaporization of the refrigerant liquid 80; and a step of adjusting supply amount of the refrigerant liquid 80 so that the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M) at a rated operation.

As one embodiment of the present invention, further, it is more preferable to comprise a step of activating the controlling part 20 to stop supplying of the refrigerant liquid 80 to the air space 40 so that the temperature of the cylindrical coil 100 at least does not fall below the minimum temperature t_(N) where the refrigerant liquid 80 vaporizes, and further comprise a step of repeating the above step and the step of supplying the refrigerant liquid 80 to the air space 40 so as to maintain the temperature of the cylindrical coil 100 in a range between the allowable maximum temperature t_(M) and the minimum temperature t_(N).

As another embodiment of the present invention, it may be the driving method, in which, as shown in FIG. 5, the controlling part 20 further comprises a coil temperature detecting sensor 21 for detecting a temperature of the cylindrical coil 100, a pump 22 for supplying the refrigerant liquid 80, and a controller 23 for adjusting supply amount of the refrigerant liquid 80 with on/off command to the pump 22, and the method comprises a step of activating the coil temperature detecting sensor 21 to detect a temperature of the cylindrical coil 100, a step of having the controller 23 activate the pump 22 in coordination with the above step to supply the refrigerant liquid 80 to the air space 40, and a step of adjusting supply amount of the refrigerant liquid 80.

As a further embodiment of the present invention, it also may be the driving method, in which, as shown in FIG. 6, the controlling part 20 comprises a coil temperature detecting sensor 21 for detecting a temperature of the cylindrical coil 100, an electromagnetic valve 24 for supplying the refrigerant liquid 80 to the air space 40 from the refrigerant liquid container 81 arranged at a position higher than the cylindrical coil 100, in coordination with the coil temperature detecting sensor 21, and a controller 23 for adjusting supply amount of the refrigerant liquid 80 with open/close command to the electromagnetic valve 24, and the method comprises a step of activating the coil temperature detecting sensor 21 to detect a temperature of the cylindrical coil 100, a step of having the controller 23 activate the electromagnetic valve 24 in coordination with the above step to supply the refrigerant liquid from the refrigerant liquid container 81 to the air space 40, and a step of adjusting supply amount of the refrigerant liquid 80.

As another embodiment of the present invention, further, as shown in FIG. 5 or FIG. 6, it also may be the driving method which further comprises a step of having the controlling part 20 activate the circulating means 82 to collect the refrigerant liquid 80 in a gas phase 800 into the refrigerant liquid container 81 in a liquid phase 80 thereof.

As another embodiment of the present invention, further, it also may be the driving method of the coreless rotating electrical machine 10 in which a drive shaft 1000 is fixed to a center part 340 of the cylindrical mount 300, and rotatably coupled to a center part 240 of the lid-type mount 200.

The fourth aspect of the present invention is a driving method of a coreless rotating electrical machine 10 for being operated under a load exceeding a rating, shown in FIG. 3 and FIG. 4.

The coreless rotating electrical machine 10 forms a first air space 40 including an air gap by a stator 2 consisting of a lid-type mount 200 which fixes one of end faces 101 of an energizable coreless cylindrical coil 100, and a rotor 3 consisting of a cup-type mount 400 opposingly and rotatably positioned with respect to the lid-type mount 200, wherein the cup-type mount 400 included in the rotor 3 has a bottom part 410 open at one end and closed at the other end, to which concentric inner yoke 420 and outer yoke 430 are integrated, and the rotor is equipped with a plurality of magnets 4 with intervals 41 with respect to each other in a circumferential direction on an outer surface 422 of the inner yoke 420 and/or an inner surface 431 of the outer yoke 430, and provided with slits 423, each of which passing through the inner yoke 420, at positions of the inner yoke 420 corresponding to each of the intervals 41.

Further, it is the driving method for operating the cureless rotating electrical machine 10 under the load exceeding the rating, in which the cylindrical coil 100 is arranged in a first air space 40 as suspended such that the other end face 102 of the cylindrical coil 100 leaves a clearance 411 between the bottom 410 of the cup-type mount 400; a second air space 50 is formed between one of end faces 401 of the cup-type mount 400 and the lid-type mount 200 at an inner periphery side 110 of the cylindrical coil 100; a third air space 60 is formed at an outer periphery side 120 of the cylindrical coil 100; a channel 8 for supplying a refrigerant liquid 80 to the first air space 40 is provided on the stator 2, and a controlling part 20 related to the stator 2, and a driving part 30 related to the rotor 3 are equipped therewith.

Further, in the driving method of the present invention, the coreless rotating electrical machine 10 can be equipped, on the stator 2, with a refrigerant liquid container 81 which is in communication with a channel 8, and further equipped with a circulating means 82 which communicates between the refrigerant liquid container 81 and the first air space 40.

As apparent from the fourth aspect of the present invention, the method is characterized in that it comprises a step of activating the driving part 30 and operating the coreless rotating electrical machine 10 under the load exceeding the rating, a step of activating the controlling part 20 to supply the refrigerant liquid 80 to inside 421 of the inner yoke 420 of the first air space 40 so as to feed the refrigerant liquid 80 to the cylindrical coil 100, which generates heat, via the slits 423, a step of allowing the cylindrical coil 100, which generates heat, to vaporize the refrigerant liquid 80 so as to cool itself by latent heat of vaporization of the refrigerant liquid 80, and a step of adjusting supply amount of the refrigerant liquid 80 so that the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M) at a rated operation.

As one embodiment of the present invention, further, it is preferable to comprise a step of activating the controlling part 20 to stop supplying of the refrigerant liquid 80 to the first air space 40 so that the temperature of the cylindrical coil 100 at least does not fall below the minimum temperature t_(N) where the refrigerant liquid 80 vaporizes, and further comprise a step of repeating the above step and the step of supplying the refrigerant liquid 80 to inside 421 of the inner yoke 420 of the first air space 40 so as to feed the refrigerant liquid 80 to the cylindrical coil 100, which generates heat, via the slits 423 so as to maintain the temperature of the cylindrical coil 100 in a range between the allowable maximum temperature t_(M) and the minimum temperature t_(N).

As another embodiment of the present invention, it may be the driving method, in which as shown in a schematic diagram of FIG. 5, the controlling part 20 further comprises a coil temperature detecting sensor 21 for detecting a temperature of the cylindrical coil 100, a pump 22 for supplying the refrigerant liquid 80, and a controller 23 for adjusting supply amount of the refrigerant liquid 80 with on/off command to the pump 22, and the method comprises a step of activating the coil temperature detecting sensor 21 to detect a temperature of the cylindrical coil 100, a step of having the controller 23 activate the pump 22 in coordination with the above step to supply the refrigerant liquid 80 to inside 421 of the inner yoke 420 of the first air space 40 so as to feed the refrigerant liquid 80 to the cylindrical coil 100, which generates heat, via the slits 423, and a step of adjusting supply amount of the refrigerant liquid 80.

As a further embodiment of the present invention, it also may be the driving method, in which, as shown in a schematic diagram of FIG. 6, the controlling part 20 comprises a coil temperature detecting sensor 21 for detecting a temperature of the cylindrical coil 100, an electromagnetic valve 24 for supplying the refrigerant liquid 80 to the first air space 40 from the refrigerant liquid container 81 arranged at a position higher than the cylindrical coil 100, in coordination with the coil temperature detecting sensor 21, and a controller 23 for adjusting supply amount of the refrigerant liquid 80 with open/close command to the electromagnetic valve 24, and the method comprises a step of activating the coil temperature detecting sensor 21 to detect a temperature of the cylindrical coil 100, a step of having the controller 23 activate the electromagnetic valve 24 in coordination with the above step to supply the refrigerant liquid 80 to inside 421 of the inner yoke 420 of the first air space 40 so as to feed the refrigerant liquid 80 to the cylindrical coil 100, which generates heat, via the slits 423, and a step of adjusting supply amount of the refrigerant liquid 80.

As another embodiment of the present invention, further, as shown in FIG. 5 or FIG. 6, it may be the driving method which further comprises a step of having the controlling part 20 activate the circulating means 82 to collect the refrigerant liquid 80 in a gas phase 800 into the refrigerant liquid container 81 in a liquid phase 80.

As another embodiment of the present invention, further, it also may be the driving method of the cureless rotating electrical machine 10 in which a drive shaft 1000 is fixed to a center part 440 of the cup-type mount 400, and rotatably coupled to a center part 240 of the lid-type mount 200.

As one embodiment in the third and fourth aspects of the present invention, it is preferred that the cylindrical coil 100 is made from what formed to a cylindrical form by either of a laminate of electrically conductive metal sheets having linear parts being spaced in an axial direction covered with insulating layers, or a linear conductor covered with an insulating layer.

As another embodiment in the third and fourth aspects of the present invention, it is preferred that the refrigerant liquid 80 is any of water, ethanol, ammonia, liquid nitrogen, liquid helium or fluorinated liquid.

The fifth aspect of the present invention is a driving system 1 for operating a coreless rotating electrical machine 10 under a load exceeding a rating, wherein the coreless rotating electrical machine 10 is shown by each of the schematic diagrams of FIGS. 1 and 2, and the driving system 1 is shown by each of the schematic diagrams of FIGS. 5 and 6.

It is the driving system 1 for operating be coreless rotating electrical machine 10 under a load exceeding a rating, wherein the driving system consists of the coreless rotating electrical machine 10 in which an air space 40 including an air gap is formed by a stator 2 consisting of a lid-type mount 200 which fixes an end face 101 of the energizable coreless cylindrical coil 100 and a rotor 3 having a cylindrical mount 300 opposingly and rotatably positioned with respect to the lid-type mount 200 with a plurality of magnets 4 equipped on an inner surface 310 of the cylindrical mount 300, and having a channel 8 for supplying refrigerant liquid 80 to the air space 40, provided on the stator 2; a driving device 30 which is activated in coordination with the rotor 3 to drive the coreless rotating electrical machine 10; and a controlling device 20 which supplies the refrigerant liquid 80 to the air space 40 in coordination with a coil temperature detecting sensor 21 which detects a temperature of the cylindrical coil 100, equipped on the stator 2.

Further, in the driving system 1 of the present invention, the coreless rotating electrical machine 10 can also be equipped, on the stator 2, with a refrigerant liquid container 81 which is in communication with the channel 8, and a circulating means 82 which communicates between the refrigerant liquid container 81 and the first air space 40.

As apparent from the fifth aspect of the present invention, the driving system 1 is characterized in that, when activating the driving part 30 and operating the coreless rotating electrical machine 10 under the load exceeding the rating, such operation is enabled by activating the controlling part 20 to adjust supply amount of the refrigerant liquid 80 so that the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M) at a rated operation, in which the refrigerant liquid 80 is supplied to the air space 40 to allow the cylindrical coil 100, which generates heat, to vaporize the refrigerant liquid 80 so as to cool itself by latent heat of vaporization of the refrigerant liquid 80.

As one embodiment of the present invention, it is more preferable that, when the driving system 1 operates the coreless rotating electrical machine 10 under the load exceeding the rating, an operation of activating the controlling device 20 to supply the refrigerant liquid 80 to the air space 40 so that the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M) at a rated operation, and an operation to stop supplying of the refrigerant liquid 80 to the air space 40 so that the temperature of the cylindrical coil 100 at least does not fall below the minimum temperature t_(N) where the refrigerant liquid 80 vaporizes by the above operation are repeated so as to maintain the temperature of the cylindrical coil 100 in a range between the allowable maximum temperature and the minimum temperature t_(N).

As another embodiment of the present invention, as shown in FIG. 5, it may be the driving system 1 in which the controlling device 20 comprises a pump 22 for supplying the refrigerant liquid 80, and a controller 23 for adjusting supply amount of the refrigerant liquid 80 with on/off command to the pump 22, wherein the controller 23 activates the pump 22 in coordination with the coil temperature detecting sensor 21 so as to supply the refrigerant liquid 80 to the air space 40 and also to adjust supply amount of the refrigerant liquid 80.

As a further embodiment of the present invention, it may be the driving system 1, as shown in FIG. 6, in which the controlling device 20 comprises an electromagnetic valve 24 for supplying the refrigerant liquid 80 and a controller 23 for adjusting supply amount of the refrigerant liquid 80 with open/close command to the electromagnetic valve 24, wherein the electromagnetic valve 24 is activated in coordination with the coil temperature detecting sensor 21 to supply the refrigerant liquid 80 to the air space 40 from the refrigerant liquid container 81 arranged at a position higher than the cylindrical coil 100, and also to adjust supply amount of the refrigerant liquid 80.

As another embodiment of the present invention, further, as shown in FIG. 5 or FIG. 6, it may be the driving system 1 in which the controlling device 20 activates the circulating means 82 to collect the refrigerant liquid 80 in a gas phase 800 into the refrigerant liquid container 81 in a liquid phase 80.

As another embodiment of the present invention, further, it also may be the driving system 1 consisting of the coreless rotating electrical machine 10 in which a drive shaft 1000 is equipped as being fixed to a center part 340 of the cylindrical mount 300, and rotatably coupled to a center part 240 of the lid-type mount 200.

The sixth aspect of the present invention is a driving system 1 for operating a coreless rotating electrical machine 10 under a load exceeding a rating, wherein the coreless rotating electrical machine 10 is shown by each of the schematic diagrams of FIGS. 3 and 4, and the driving system 1 is shown by each of the schematic diagrams of FIGS. 5 and 6.

It forms an air space 40 including an air gap by a stator 2 consisting of a lid-type mount 200 which fixes one of end faces 101 of an energizable coreless cylindrical coil 100, and a rotor 3 consisting of a cup-type mount 400 opposingly and rotatably positioned with respect to the lid-type mount 200, wherein the cup-type mount 400 included in the rotor 3 has a bottom part 410 open at one end and closed at the other end, to which concentric inner yoke 420 and outer yoke 430 are integrated, the rotor is equipped with a plurality of magnets 4 with intervals 41 with respect to each other in a circumferential direction of an outer surface 422 of the inner yoke 420 and/or an inner surface 431 of the outer yoke 430, and provided with slits 423, each of which passing through the inner yoke 420, at positions of the inner yoke 420 corresponding to each of the intervals 41.

Further, it is the driving system 1 for operating the coreless rotating electrical machine 10 under a load exceeding a rating, wherein the driving system 1 consists of: the coreless rotating electrical machine 10, in which the cylindrical coil 100 is arranged in a first air space 40 as suspended such that the other end face 102 of the cylindrical coil 100 leaves a clearance 411 between the bottom 410 of the cup-type mount 400, a second air space 50 is formed between one of end faces 401 of the cup-type mount 400 and the lid-type mount 200 at an inner periphery side 110 of the cylindrical coil 100, a third air space 60 is formed at an outer periphery side 120 of the cylindrical coil 100, and a channel 8 for supplying a refrigerant liquid 80 to the first air space 40 is provided on the stator 2; a driving device 30 which is activated in coordination with the rotor 3 to drive the coreless rotating electrical machine 10; and a controlling part 20 which is activated in coordination with a coil temperature detecting sensor 21 equipped on the stator 2 to supply a refrigerant liquid 80 to an air space 40.

Further, in the driving system 1 of the present invention, the cureless rotating electrical machine 10 can also be equipped, on the stator 2, with a refrigerant liquid container 81 which is in communication with the channel 8, and a circulating means 82 which communicates between the refrigerant liquid container 81 and the first air space 40.

As apparent from the sixth aspect of the present invention, the driving system 1 is characterized in that, when activating the driving part 30 and operating the cureless rotating electrical machine 10 under the load exceeding the rating, such operation is enabled by activating the controlling part 20 to adjust supply amount of the refrigerant liquid 80 so that the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M) at a rated operation, in which the refrigerant liquid 80 is supplied to inside 421 of the inner yoke 420 of the first air space 40 to allow the cylindrical coil 100, which generates heat, to vaporize the refrigerant liquid 80 fed to the cylindrical coil 100 via the slits 423 so as to cool itself by latent heat of vaporization of the refrigerant liquid 80.

As one embodiment of the present invention, it is more preferable that, when the driving system 1 operates the coreless rotating electrical machine 10 under the load exceeding the rating, an operation of activating the controlling device 20 to supply the refrigerant liquid 80 to inside 421 of the inner yoke 420 of the first air space 40 so that the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M) at a rated operation, and an operation to stop supplying of the refrigerant liquid 80 to the first air space 40 so that the temperature of the cylindrical coil 100 at least does not fall below the minimum temperature t_(N) where the refrigerant liquid 80 vaporizes by the above operation, are repeated so as to maintain the temperature of the cylindrical coil 100 in a range between the allowable maximum temperature t_(M) and the minimum temperature t_(N).

As another embodiment of the present invention, as shown in FIG. 5, it may be the driving system 1 in which the controlling device 20 comprises a pump 22 for supplying the refrigerant liquid 80 to inside 421 of the inner yoke 420 of the first air space 40, and a controller 23 for adjusting supply amount of the refrigerant liquid 80 with on/off command to the pump 22, wherein the controller 23 activates the pump 22 in coordination with the coil temperature detecting sensor 21 and supplies the refrigerant liquid 80 to inside 421 of the inner yoke 420 of the first air space 40 so as to feed the refrigerant liquid 80 to the cylindrical coil 100, which generates heat, via the slits 423 and also to adjust supply amount of the refrigerant liquid 80.

As a further embodiment of the present invention, it may be the driving system 1, as shown in FIG. 6, in which the controlling part 20 comprises an electromagnetic valve 24 for supplying the refrigerant liquid 80 to inside 421 of the inner yoke 420 of the first air space 40 and a controller 23 for adjusting supply amount of the refrigerant liquid 80 with open/close command to the electromagnetic valve 24, wherein the controller 23 activates the electromagnetic valve 24 in coordination with the coil temperature detecting sensor 21, and the refrigerant liquid 80 is supplied to inside 421 of the inner yoke 420 of the first air space 40 from the refrigerant liquid container 81 arranged at a position higher than the cylindrical coil 100 so as to feed the refrigerant liquid 80 to the cylindrical coil 100, which generates heat, via the slits 423 and also to adjust supply amount of the refrigerant liquid 80.

As another embodiment of the present invention, further, as shown in FIG. 5 or FIG. 6, it may be the driving system 1 in which the controlling part 20 activates the circulating means 82 to collect the refrigerant liquid 80 in a gas phase 800 into the refrigerant liquid container 81 in a liquid phase 80.

As another embodiment of the present invention, it also may be the driving system 1 consisting of the coreless rotating electrical machine 10 in which a drive shaft 1000 is equipped as being fixed to a center part 440 of the cup-type mount 400, and rotatably coupled to a center part 240 of the lid-type mount 200.

In the driving system 1 of the present invention, it is preferred that the cylindrical coil 100 of the coreless rotational electrical machine 10 is made from what formed to a cylindrical form by either of a laminate of an electrically conductive metal sheet having linear parts being spaced in a longitudinal direction covered with insulating layers, or a linear conductor covered with an insulating layer.

In the driving system 1 of the present invention, it is preferred that the refrigerant liquid 80 is any of water, ethanol, ammonia, liquid nitrogen, liquid helium or fluorinated liquid.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a cross sectional schematic diagram of a coreless rotating electrical machine comprising a rotor consisting of a cylindrical mount opposingly and rotatably positioned with respect to a stator consisting of a lid-type mount including a cylindrical coil, which is an embodiment of the present invention.

FIG. 2 is a perspective diagram of a partially cutout cureless rotating electrical machine shown in FIG. 1.

FIG. 3 is a cross sectional schematic diagram of a coreless rotating electrical machine comprising a rotor consisting of a cup-type mount opposingly and rotatably positioned with respect to a stator consisting of a lid-type mount including a cylindrical coil, which is another embodiment of the present invention.

FIG. 4 is a perspective diagram of a partially cutout coreless rotating electrical machine shown in FIG. 3.

FIG. 5 is a schematic diagram representing the coreless rotating electrical machine, a driving method thereof, and a driving system including thereof, comprising a controlling part or controlling device, for controlling flow volume of a refrigerant liquid by a pump, equipped in relation to the stator, and a driving part or driving device equipped in relation to the rotor, of the cureless rotating electrical machine shown in FIG. 1 or 3.

FIG. 6 is a schematic diagram representing the cureless rotating electrical machine, a driving method thereof, and a driving system including thereof, comprising a controlling part or controlling device, for controlling flow volume of a refrigerant liquid by an electromagnetic valve, equipped in relation to the stator, and a driving part or driving device equipped in relation to the rotor, of the coreless rotating electrical machine shown in FIG. 1 or 3.

FIG. 7 is a schematic diagram of a driving test of a measured motor (CP50) of the coreless rotating electrical machine comprising a rotor consisting of a cup-type mount opposingly and rotatably positioned with respect to a stator consisting of the lid-type mount including a cylindrical coil.

FIG. 8 is a detailed diagram representing dimensions of the measured motor (CP50) shown in FIG. 7.

FIG. 9 is what has excerpted a shift of load torque and a shift of temperature t of the cylindrical coil with respect to time (seconds) from start-up up to when 720 seconds (12 minutes) has passed in a case where applied voltage of the measured motor (CP50) is set to 24V, and a torque, with which the temperature of the cylindrical coil does not exceed an allowable maximum temperature t_(M) (=130° C.), even if the measured motor (CP50) is operated without the refrigerant liquid (pure water) supplied to the cylindrical coil, is used as a rated torque of the measured motor (CP50).

FIG. 10 is a control flow of supplying a refrigerant liquid, in which a load of the measured motor (CP50) is raised by a variable load of an electric generator via a torque sensor shown in FIG. 7, the measured motor is operated such that a temperature difference _(Δ)t between the maximum temperature t_(c1) of the cylindrical coil under control and the minimum temperature t_(c2) of the cylindrical coil under control comes narrow, under a condition where the temperature of the cylindrical coil does not exceed the allowable maximum temperature t_(M) and does not fall below the minimum temperature t_(N) where the refrigerant liquid (pure water) vaporizes, and the maximum torque and refrigerant liquid flow volume are measured, in a case where applied voltage of the measured motor (CP50) is set to 24V.

FIG. 11 is a table of current (Arms), rotational speed (rpm), output (W), pump conveyed amount (ml/min), total pump activation time (sec) in 10 minutes and refrigerant (pure water) amount (ml) in 10 minutes when the measured motor (CP50) is driven with respective load torque T (T₁=0.33 Nm, T₂=0.36 Nm, T₃=0.39 Nm, T₄=0.42 Nm) exceeding the rated torque.

FIG. 12 is a graph of the current (Arms) and the refrigerant (pure water) amount (ml) in 10 minutes with respect to the load torque T of FIG. 11.

FIG. 13 represents a shift of temperature t of the cylindrical coil, a shift of on/off timing of the pump and a shift of temperature t of the cylindrical coil, a shift of on/off pulse of the pump during a period from start-up up to when 180 to 360 seconds has passed from then, in a case of the load torque T=0.33 Nm.

FIG. 14 represents a shift of temperature t of the cylindrical coil, a shift of on/off pulse of the pump, and a shift of temperature t of the cylindrical coil, a shift of on/off pulse of the pump during a period from start-up up to when 180 to 360 seconds has passed from then, in a case of the load torque T=0.39 Nm.

FIG. 15 represents a shift of temperature t of the cylindrical coil, a shift of on/off pulse of the pump, and a shift of temperature t of the cylindrical coil, a shift of on/off pulse of the pump during a period from start-up up to when 180 to 360 seconds has passed from then, in a case of the load torque T=0.39 Nm.

FIG. 16 represents a shift of temperature t of the cylindrical coil, a shift of on/off pulse of the pump, and a shift of temperature t of the cylindrical coil, a shift of on/off pulse of the pump during a period from start-up up to when 180 to 360 seconds has passed from then, in a case of the load torque T=0.42 Nm.

FIG. 17 represents a shift of temperature t of the cylindrical coil, a shift of on/off pulse of the pump, and a shift of temperature t of the coil and a shift of on/off pulse of the pump during a period from start-up up to when 180 to 420 seconds has passed from then, in a case where the load torque is changed as T₁=0.33 Nm (300 seconds), T₄=0.42 Nm (300 seconds) and then T₁=0.33 Nm (120 seconds).

FIG. 18 represents a shift of temperature t, a shift of on/off pulse of the pump, and a shift of temperature t of the coil and a shift of on/off pulse of the pump during a period from start-up up to when 180 to 420 seconds has passed from then, in a case where the measured motor (CP50), of which load torque is changed as shown in FIG. 17, is set such that a supply start temperature t_(L1) of refrigerant liquid is 110° C. (the refrigerant liquid is supplied at a temperature t exceeding such temperature), and a supply stop temperature of refrigerant liquid t_(L2) is 90° C. (the supply of the refrigerant liquid is stopped at a temperature t which falls below such temperature).

FIG. 19 is a list of melting temperature ° C., boiling temperature ° C., vaporization heat kJ/kg of representative refrigerant liquids.

FIG. 20 represents a shift of temperature t of the cylindrical coil in a driving test using the measure motor (CP50) in which a fluorinated refrigerant is used with load torque T 0.317 Nm, with respect to each of cases where cooling is performed and where cooling is not performed.

FIG. 21 (Reference diagram) is a coreless rotating electric machine having a configuration in which a refrigerant liquid is supplied only to a second air space of the coreless rotating electrical machine.

The inventors of the present invention have confirmed that a continuous operation of a coreless motor (CP50) is possible by completely controlling a temperature of a cylindrical coil, which is an armature coil, with a load exceeding a rated torque T₀=0.28 Nm being continuously applied to the coreless motor (CP50).

A feature of a basic structure of a coreless rotating electrical machine 10 (hereinafter referred as “coreless motor 10”) equipped with a stator 2 comprising a cylindrical coil 100 of the present invention is that, firstly, a cylindrical coil 100 is used as an armature coil which one end is fixed to a stator 2, wherein the cylindrical coil 100 is made with a laminate of electrically conductive metal sheets having linear parts being spaced in a longitudinal direction covered with insulating layers, or a linear conductor covered with an insulating layer, formed to a cylindrical form. It is an energizable cureless cylindrical coil, preferably having a certain rigidity with a thickness, consisting of two layers or four layers, of 5 mm or less.

A second feature of the basic structure is that, it is a coreless motor 10 having a structure in which one of end faces of the cylindrical coil 100 is closed by an inner surface of a lid-type mount 200 included in the stator 2, and the other end face of the cylindrical coil 100, which is open, is inserted as suspended in an air space or a first air space 40 including an air gap in which a magnetic field is formed by a bottom of a cylindrical mount 300 or a cup-type mount 400 of the rotor 3 consisting of a magnetic body and an inner surface of the cylindrical mount 300 or an outer yoke 430 of the cup-type mount 400 equipped with a plurality of magnets (permanent magnets) 4.

Then, by feeding a refrigerant liquid 80 to an inner face of the cylindrical coil 100, or inside of an inner yoke 420 of the rotor 3 consisting of the cup-type mount 400, the refrigerant liquid 80 is vaporized at the inner face of the cylindrical coil 100, which generates heat, when it passes through the air gap in which the magnetic field is formed. The cylindrical coil 100 is thereby cooled at the inner face with latent heat of vaporization, and entire cylindrical coil including an outer face is instantaneously cooled by heat transfer. This is one of the features of a cooling structure of the coreless motor of the present invention.

A third feature of the basic structure is that a controlling part or controlling device 20, which is activated when the coreless motor 10 is operated under a load exceeding a rating, is arranged in association with the stator 2, and that it comprises a coil temperature detecting sensor 21 for detecting temperature increase of the cylindrical coil 100 in operation. This feature is to have the controlling part or controlling device 20 adjust supply amount of the refrigerant liquid 80 so that the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M) under rated operation, in coordination with the coil temperature detecting sensor 21. The coreless motor 10 which continuously operates under the load exceeding the rating is achieved thereby. Driving tests considering various overload conditions are performed for the coreless motor 10 of the present invention as shown in FIGS. 13 to 18 and FIG. 20.

FIG. 7 is a schematic diagram of a driving test apparatus of a measured motor (CP50) based on one embodiment of the coreless rotating electrical machine 10 equipped with the rotor 3 consisting of the cup-type mount 400 opposingly and rotatably positioned with respect to the stator 2 consisting of the lid-type mount 200 including the cylindrical coil 100. FIG. 8 is a detailed diagram of an actually measured structure of the measured motor (CP50).

As apparent from FIG. 7, an output axis 1000, which diameter Φ is 6 mm, of the coreless motor 10 which is the measured motor (CP50) is coupled to an electric generator 32 (m-link CPH80-E) via a torque sensor 34 (UNIPULSE UTM II-5 Nm) to which a torque meter 35 (UNIPULSE TM301) is connected. The electric power generated by the electric generator 32 is made to be consumed by a variable load 33 (in-link VL300), and an arbitrary load is applied to the coreless motor 10 to drive thereof. Current of the coreless motor 10 is measured with a power meter 31 (HIOKI PW3336) which is arranged between a driving part or driving device 30 (a three-phase PWM type, in-link MLD750-ST) and the coreless motor 10. Current I(A), Voltage V(V) and Electric power Pi(W) can be measured by the power meter 31.

Then, temperature t and voltage is input to the controlling part or controlling device 20 (m-link TH300) including a CPU via a device (GRAPHTEC GL-100) which records the temperature t and voltage measured by the coil temperature detecting sensor 21 arranged on the cylindrical coil 100. The controlling part or controlling device 20 activates a refrigerant liquid supply pump 22 (NITTO UPS-112) at an appropriately set temperature t, deactivates the pump, and the refrigerant liquid 80 is supplied to the first air space 40 of the coreless motor 10 from a refrigerant liquid container 81. Flow volume of the refrigerant liquid 80 is made to be adjusted by varying driving voltage of the refrigerant liquid supply pump 22 using a refrigerant liquid flow volume varying device 26 (TOKYO-RIKOSHA TYPE RSA-5) equipped in association with the controlling part or controlling device 20. The coreless motor 10 is further provided with a channel 8 including a pipe 82 and a plurality of slits 423 in the inner yoke 420 of the rotor 3 in an axial direction.

Dimensions of the coreless motor 10 which is the measured motor shown in FIG. 8 are overviewed. An axial length of the output axis coupled and fixed to the stator 2 and rotatably coupled to the rotor 3 is L=81.7 mm. A side of a rectangular bottom of the stator 2 is x=50 mm, an outer diameter of the outer yoke of the rotor 3 is Φ=46.3 mm, an inner diameter is Φ=40 mm, and a thickness is Δ=3.15 mm. A diameter of a rotor axis part is Φ=22.5 mm, which corresponds to an inner diameter Φ of the inner yoke 420. An outer diameter thereof is Φ=27.5 mm, and a thickness is Δ=2.5 mm. A thickness of each of the four magnets 4 equipped on the inner face of the outer yoke 430 is Δ=3.5 mm. A width of the air gap formed by the inner yoke 420 and the outer yoke 430 is Ψ=2.75 mm, and a width of the cylindrical coil 100 equipped as suspended in the air gap is Δ=1.50 mm.

The driving test using the coreless motor 10 which is the measured motor (CP50) is to verify a function effect obtained by directly spraying pure water 80, which is the refrigerant liquid, to the cylindrical coil 100, which generates heat, for cooling thereof by latent heat of vaporization of the pure water 80, and that the continuous operation of the coreless motor 10 is possible even under the load condition exceeding the rating by such cooling function.

A test procedure of the coreless motor 10 is as follows. Voltage V₀=24(V) is set as applied voltage to the driving part or driving device 30 (three-phase PWM type, m-link MLD750-ST) (hereinafter referred as “driving device 30”) shown in FIG. 7. It is also possible to perform the test by setting the voltage V₀ as 36(V) and/or 48(V), higher than 24(V), with the same work, and needless to say, results may be of course different in each of the cases.

Next, a load torque T applied to the coreless motor 10 is raised with the variable load 33 of the electric generator 32. The flow volume of the refrigerant liquid (pure water) 80 is adjusted so as to be corresponded with the setting of load torque T by varying the driving voltage of the refrigerant liquid supply pump 22 using the refrigerant liquid flow volume varying device 26 equipped in association with the controlling part or controlling device 20 (hereinafter referred as “controlling device 20”). The allowable maximum temperature of the cylindrical coil 100 used in the coreless motor 10 is 130° C. Therefore, the adjustment is performed by operating the coreless motor such that the temperature difference _(Δ)t between the maximum temperature t_(c1) of the cylindrical coil under control and the minimum temperature t_(c2) of the cylindrical coil under control comes narrow, under a condition where the temperature of the cylindrical coil does not exceed the allowable maximum temperature t_(M)=130° C., and does not fall below the minimum temperature t_(N), where the refrigerant liquid (pure water) vaporizes to measure the load torque T and the flow volume of the refrigerant liquid (pure water) 80 at such point.

FIG. 10 is a control flow in which the load of the measured motor (CP50) 10 is raised with the variable load 33 of the electric generator 32 via the torque sensor 34 shown in FIG. 7 to have the coreless motor 10 operated such that the temperature difference _(Δ)t between the maximum temperature t_(c1) of the cylindrical coil under control and the minimum temperature t_(c2) of the cylindrical coil under control comes narrow, under a condition where the temperature of the cylindrical coil does not exceed the allowable maximum temperature t_(M)=130° C. and does not fall below the minimum temperature t_(N) where the refrigerant liquid (pure water) vaporizes.

As apparent from FIG. 10, the coil temperature detecting sensor 21 is read (first read-in), and when the temperature t of the cylindrical coil 100 exceeds t_(L1)=123° C., the refrigerant liquid supply pump 22 is operated to supply the refrigerant liquid. The coil temperature detecting sensor 21 is read (second read-in) further, and when the temperature t of the cylindrical coil 100 falls below t_(L2)=122° C., the refrigerant liquid supply pump 22 is deactivated to stop supply of the refrigerant liquid. During such period, in a case where the temperature t of the cylindrical coil does not reach such set temperatures, the first read-in and the second read-in of the coil temperature detecting sensor 21 are repeated.

The maximum torque T_(M), when the applied voltage to the driving device 30 of the coreless motor 10 is set to 24V, is thus measured, and the flow volume L_(M) per minute of the refrigerant liquid (pure water) 80 at such point measured. Operating conditions of the refrigerant liquid supply pump 22 are as in the followings.

(1) Cooling start temperature t_(L1)=123° C. (the first read-in)

(2) Cooling stop temperature t_(L2)=122° C. (the second read-in)

When the refrigerant liquid supply pump 22 is switched with respective read-in conditions of (1) and (2) to activate the coreless motor 10, values are: the torque T_(M)=0.42 Nm and the flow volume L_(M)=1.141 ml/min.

A technical basis for using the maximum torque T_(M) and the maximum flow volume L_(M) is as follows: when the coreless motor is operated with a torque T exceeding 0.42 Nm, the flow volume of the refrigerant liquid 80 also increases. However, we have confirmed that, with the increase of the refrigerant liquid 80, the refrigerant liquid 80 is discharged in a form of a mist (liquid phase) to outside of the coreless motor 10 without being vaporized by the cylindrical coil 100. Therefore, the torque T=0.42 Nm becomes a critical torque which allows the coreless motor 10 to be operated continuously under a load exceeding the rated torque T₀=0.28 Nm.

FIG. 9 represents a torque which allows the coreless motor to be continuously operated without supplying the pure water 80, which is the refrigerant liquid, thereto, and with which the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M)=130° C. When the coreless motor 10 is continuously operated under the load torque T₀=0.28 Nm, as apparent form FIG. 9, the temperature of the cylindrical coil 100 reaches 100° C. in 50 seconds, and exceeds 120° C. in 300 seconds (5 minutes). The temperature reaches 127° C. in 720 seconds (12 minutes), and later, temperature equilibration is achieved at the allowable maximum temperature t_(M)=130° C. or less. FIG. 9 simply represents that the rated torque T₀, which allows the coreless motor to be continuously operated when the refrigerant liquid is not supplied, is T₀=0.28 Nm.

Next, a load torque T exceeding the rated torque T₀ is applied to the coreless motor 10 when the applied voltage to the driving device 30 is set to 24V. Then, as apparent form FIG. 12, the current increases in proportion to the raised load torque T, and with heat generation of the cylindrical coil 100 associated therewith, a supply amount of the refrigerant liquid (pure water) 80 is increased. Thus, it is confirmed that, as a result of an appropriate control of the driving system 1, the continuous operation under the overload condition is possible.

Specifically, the coreless motor 10 is activated in 5 cases in which the load torque T, for continuously operating the coreless motor 10 under the load exceeding the rated torque T₀, is set to T₁=0.33 Nm, T₂=0.36 Nm, T₃=0.39 Nm, T₄=T_(M)=0.42 Nm, and further, set to T₄=0.42 Nm and lowered to T₁=0.33 Nm and then set to T₄=0.42 Nm again.

It is confirmed that, a normal continuous operation of the coreless motor 10 is possible under any set torque exceeding the rated torque T₀ with a control by the controlling device 20 in which the refrigerant liquid supply pump 22 is switched such that, at the cooling start temperature t_(L1)=123° C. (the first read-in), the refrigerant liquid is supplied at a temperature t exceeding the cooling start temperature, and at the cooling stop temperature t_(L2)=122° C. (the second read-in), the supply of the refrigerant liquid is stopped at a temperature t below such temperature, so that the temperature difference _(Δ)t between the maximum temperature t_(c1) of the cylindrical coil under control and the minimum temperature t_(c2) of the cylindrical coil under control comes narrow, under a condition where the temperature of the cylindrical coil does not exceed the allowable maximum temperature t_(M)=130° C. thereof and does not fall below the minimum temperature t_(N) where the refrigerant liquid (pure water) vaporizes.

The operation condition of the refrigerant liquid supply pump 22 is made as: cooling start (first read-in) temperature t_(L1)=123° C. This is a set value which allows temperature increase due to overshoot at a time when the cooling started, and which the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M)=130° C. In addition, the cooling stop (the second read-in) temperature is made as t_(L2)=122° C. This is a set value which allows temperature decrease due to overshoot at a time when the cooling stopped, and further, which prevents malfunction due to foreign noise etc. for operating the system stably by making hysteresis with the cooling start (first read-in) temperature t_(L1)=123° C. as 1° C. With such operating conditions, the temperature difference _(Δ)t between the maximum temperature t_(c1) of the cylindrical coil under control and the minimum temperature t_(c2) of the cylindrical coil under control comes narrow, and thus, stress to the cylindrical coil due to thermal shock is alleviated, and change of electric resistance value of the cylindrical coil may be narrowed.

In the followings, results confirmed with different load torques T under identical equipments and identical control conditions are described. Each of the results is shown in FIGS. 13 to 17.

FIG. 13 is a result of a driving test of the coreless motor 10 in which the load torque T₁ is set to T₁=0.33 Nm with the variable load 33 of the electric generator 32. As apparent from FIG. 13(a), during an operation test of the coreless motor 10, the coreless motor 10 is operated such that the cylindrical coil 100 is maintained within a certain temperature range by an on/off pulse operation of the refrigerant liquid supply pump 22, with the torque T₁ maintained at 0.33 Nm. More specifically, the temperature t of the cylindrical coil 100 exceeds the cooling start temperature (t_(L1)=123° C.) in around 100 seconds after start-up of the coreless motor 10. At this moment, the refrigerant liquid (pure water) 80 is directly supplied to the cylindrical coil 100 through the slits which respectively penetrates into the inner yoke. Then, when the cylindrical coil 100 is cooled by latent heat of vaporization and falls below the cooling stop temperature (t_(L2)=122° C.), the supply of the refrigerant liquid (pure water) 80 is stopped, With repetition of such pulse operation, the temperature t of the cylindrical coil shifts in a range between 111° C. and 125° C. which is the certain temperature range. FIG. 13(a) is what has excerpted a period from when the coreless motor 10 is started up to when 720 seconds (12 minutes) has passed in a continuous operation test, and we have confirmed that the temperature shift for a period from 720 seconds (12 minutes) onward is almost similar.

FIG. 13(b) is a diagram which has enlarged a temperature waveform of the cylindrical coil 100 of 3 minutes from when 180 seconds (3 minutes) has passed from the start-up up to when 360 seconds (6 minutes) has passed from the start-up, which is after cooling has started. A condition where rapid cooling is caused can be easily determined from the figure. The first read-in temperature t_(L1) is 123° C., and when the cooling is started by supplying the refrigerant liquid 80 at a temperature t exceeding such temperature, the temperature increase due to overshoot is around within 2° C., and become reversed immediately thereafter. The second read-in temperature t_(L2) after reverse is 122° C., and even when the supply of the refrigerant 80 is stopped at a temperature t which is below such temperature, the temperature after decrease further decreases by around 11° C. to 7° C. due to overshoot. Specifically, the maximum temperature t_(c1)=125° C., the minimum temperature t_(c2)=111° C., and _(Δ)t=14° C., of the cylindrical coil under control, with the load torque set to T₁=0.33 Nm. Therefore, we have confirmed that, a normal continuous operation is possible by controlling such that the temperature difference _(Δ)t between the maximum temperature t_(c1) and the minimum temperature t_(c2) of the cylindrical coil 100 under control comes narrow, under a condition where the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M)=130° C. and does not fall below the minimum temperature t_(N) where the refrigerant liquid (pure water) vaporizes.

FIG. 14 is a result of a driving test of the coreless motor 10 in which the load torque T₂ is set to T₂=0.36 Nm with the variable load 33 of the electric generator 32. As apparent from FIG. 14(a), during the operation test of the coreless motor 10, the coreless motor 10 is operated such that the cylindrical coil 100 is maintained within a certain temperature range by the on/off pulse operation of the refrigerant liquid supply pump 22, with the torque T₂ maintained at 0.36 Nm. The temperature t of the cylindrical coil 100 exceeds the cooling start temperature (t_(L1)=123° C.) in around 90 seconds after start-up of the coreless motor 10. At this moment, the refrigerant liquid (pure water) 80 is directly supplied to the cylindrical coil 100. Then, when the cylindrical coil 100 is cooled by latent heat of vaporization and falls below the cooling stop temperature (t_(L2)=122° C.), the supply of the refrigerant liquid (pure water) 80 is stopped. With repetition of such pulse operation, the temperature t of the cylindrical coil shifts in a range between 113° C. and 128° C. which is the certain temperature range. FIG. 14(a) is what has excerpted a period from when the coreless motor 10 is started up to when 720 seconds (12 minutes) has passed in a continuous operation test, and we have confirmed that the temperature shift for a period from 720 seconds (12 minutes) onward is almost similar.

During the operation test of the coreless motor 10, a total pump operation time of 10 minutes from when the refrigerant liquid supply has started for case of the torque T₁ is 56 seconds, on the other hand, it is 85.5 seconds for the case of the torque T₂. The supply amount of the refrigerant liquid during such period is 3.62 ml for the case of the torque T₁, on the other hand, it is 5.53 ml for the case of the torque T₂, and it is 1.5 times more compared with the case of the torque T₁ (FIGS. 11 and 12).

FIG. 14(b) is a diagram which has enlarged a temperature waveform of the cylindrical coil 100 of 3 minutes from when 180 seconds (3 minutes) has passed from the start-up up to when 360 seconds (6 minutes) has passed from the start-up, which is after cooling has started. A condition where rapid cooling is caused can be easily deter fined from the figure. The first read-in temperature is t_(L1) is 123° C., and when the cooling is started by supplying the refrigerant liquid 80 at a temperature t exceeding such temperature, the temperature increase due to overshoot is around 5° C., and then reversed. The second read-in temperature t_(L2) after reverse is 122° C., and even when the supply of the refrigerant 80 is stopped at a temperature t which is below such temperature, the temperature after decrease further decreases by around 9° C. to 5° C. due to overshoot. Specifically, the maximum temperature t_(c1)=128° C., the minimum temperature t_(c2)=113° C., and _(Δ)t=15° C., of the cylindrical coil under control, with the load torque set to T₂=0.36 Nm. A pulse interval becomes shorter compared with the case for the torque T₁=0.33 Nm. We have confirmed that, a normal continuous operation is possible also for this case by controlling such that the temperature difference _(Δ)t between the maximum temperature t_(c1) and the minimum temperature t_(c2) of the cylindrical coil 100 under control comes narrow, under a condition where the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M)=130° C. and does not fall below the minimum temperature t_(N) where the refrigerant liquid (pure water) vaporizes.

FIG. 15 is a result of a driving test of the coreless motor 10 in which the load torque T3 is set to T3=0.39 Nm with the variable load 33 of the electric generator 32. As apparent from FIG. 15(a), during the operation test of the coreless motor 10, the coreless motor 10 is operated such that the cylindrical coil 100 is maintained within a certain temperature range by the on/off pulse operation of the refrigerant liquid supply pump 22, with the torque T₃ maintained at 0.39 Nm. The temperature t of the cylindrical coil 100 exceeds the cooling start temperature (tL1=123° C.) in around 50 seconds after start-up of the coreless motor 10. At this moment, the refrigerant liquid (pure water) 80 is directly supplied to the cylindrical coil 100. Then, when the cylindrical coil 100 is cooled by latent heat of vaporization and falls below the cooling stop temperature (tL2=122° C.), the supply of the refrigerant liquid (pure water) 80 is stopped. With repetition of such pulse operation, the temperature t of the cylindrical coil shifts in a range between 109° C. and 128° C. which is the certain temperature range. FIG. 15(a) is what has excerpted a period from when the coreless motor 10 is started up to when 720 seconds (12 minutes) has passed in a continuous operation test, and we have confirmed that the temperature shift for a period from 720 seconds (12 minutes) onward is almost similar.

During the operation test of the coreless motor 10, a total pump operation time of 10 minutes from when the refrigerant liquid supply has started for the case of the torque T₁ is 56 seconds, on be other hand, it is 128 seconds for the case of the torque T₃. The supply amount of the refrigerant liquid during such period is 3.62 ml for the case of the torque T₁, on the other hand, it is 8.28 ml for the case of the torque T₃, and it is 2.3 times more compared with the case of the torque T₁ (FIGS. 11 and 12).

FIG. 15(b) is a diagram which has enlarged a temperature waveform of the cylindrical coil 100 of 3 minutes from when 180 seconds (3 minutes) has passed from the start-up up to when 360 seconds (6 minutes) has passed from the start-up, which is after cooling has started. A condition where rapid cooling is caused can be easily determined from the figure. The first read-in temperature t_(L1) is 123° C., and when the cooling is started by supplying the refrigerant liquid 80 at a temperature t exceeding such temperature, the temperature increase due to overshoot is around 5° C., and then reversed. The second read-in temperature t_(L2) after reverse is 122° C., and even when the supply of the refrigerant 80 is stopped at a temperature t which is below such temperature, the temperature after decrease further decreases by around 13° C. to 5° C. due to overshoot. Specifically, the maximum temperature t_(c1)=128° C., the minimum temperature t_(c2)=109° C., and _(Δ)t=19° C., of the cylindrical coil under control, with the load torque set to T₃=0.39 Nm. A pulse interval becomes further shorter compared with the case for the torque T₂=0.36 Nm. We have confirmed that, a normal continuous operation is possible also for this case by controlling such that the temperature difference _(Δ)t between the maximum temperature t_(c1) and the minimum temperature t_(c2) of the cylindrical coil 100 under control comes narrow, under a condition where the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M)=130° C. and does not fall below the minimum temperature t_(N) where the refrigerant liquid (pure water) vaporizes.

FIG. 16 is a result of a driving test of the coreless motor 10 in which the load torque T₄ is set to T₄=0.42 Nm with the variable load 33 of the electric generator 32. As apparent from FIG. 16(a), during the operation test of the coreless motor 10, the coreless motor 10 is operated such that the cylindrical coil 100 is maintained within a certain temperature range by the on/off pulse operation of the refrigerant liquid supply pump 22, with the torque T₄ maintained at 0.42 Nm. The temperature t of the cylindrical coil 100 exceeds the cooling start temperature (t_(L1)=123° C.) in around 40 seconds after start-up of the coreless motor 10. At this moment, the refrigerant liquid (pure water) 80 is directly supplied to the cylindrical coil 100. Then, when the cylindrical coil 100 is cooled by latent heat of vaporization and falls below the cooling stop temperature (t_(L2)=122° C.), the supply of the refrigerant liquid (pure water) 80 is stopped. With repetition of such pulse operation, the temperature t of the cylindrical coil shifts in a range between 107° C. and 127° C. which is the certain temperature range. FIG. 16(a) is what has excerpted a period from when the coreless motor 10 is started up to when 720 seconds (12 minutes) has passed in a continuous operation test, and we have confirmed that the temperature shift for a period from 720 seconds (12 minutes) onward is almost similar.

During the operation test of the coreless motor 10, a total pump operation time of 10 minutes from when the refrigerant liquid supply has started for the case of the torque T₁ is 56 seconds, on the other hand, it is 176.5 seconds for the case of the torque T₄. The supply amount of the refrigerant liquid during such period is 3.62 ml for the case of the torque T₁, on the other hand, it is 11.41 ml for the case of the torque T₄, and it is 3.2 times more compared with the case of the torque T₁ (FIGS. 11 and 12).

FIG. 16(b) is a diagram which has enlarged a temperature waveform of the cylindrical coil 100 of 3 minutes from when 180 seconds (3 minutes) has passed from the start-up up to when 360 seconds (6 minutes) has passed from the start-up, which is after cooling has started, A condition where rapid cooling is caused can be easily determined from the figure. The first read-in temperature t_(L1) is 123° C., and when the cooling is started by supplying the refrigerant liquid 80 at a temperature t exceeding such temperature, the temperature increase due to overshoot is around 4° C., and then reversed. The second read-in temperature t_(L2) after reverse is 122° C., and even when the supply of the refrigerant 80 is stopped at a temperature t which is below such temperature, the temperature after decrease further decreases by around 15° C. to 7° C. due to overshoot. Specifically, the maximum temperature t_(c1)=127° C., the minimum temperature t_(c2)=107° C. and _(Δ)t=20° C., of the cylindrical coil under control, with the load torque set to T₄=0.42 Nm. A pulse interval becomes further shorter compared with the case for the torque T₃=0.39 Nm. We have confirmed that, a normal continuous operation is possible also for this case by controlling such that the temperature difference _(Δ)t between the maximum temperature t_(c1) and the minimum temperature t_(c2) of the cylindrical coil 100 under control comes narrow, under a condition where the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M)=130° C. and does not fall below the minimum temperature t_(N) where the refrigerant liquid (pure water) vaporizes.

As apparent from FIGS. 13 to 16, we have confirmed that the continuous operation of the coreless motor 10 is possible by controlling the temperature of the cylindrical coil 100, with the load torque T₁ to T₄ (0.33 to 0.42 Nm) exceeding a rated torque T₀=0.28 Nm being continuously applied to the cureless motor 10. From these test results, in any of these cases of T₁ to T₄, it is confirmed that a normal continuous operation of the cureless motor 10 is possible by controlling the temperature of the cylindrical coil 100, in which the cylindrical coil 100 vaporizes the supplied refrigerant liquid (pure water) 80, and with the latent heat of vaporization, the temperature difference _(Δ)t between the maximum temperature t_(c1) and the minimum temperature t_(c2) of the cylindrical coil 100 comes narrow, under a condition where the temperature of the cylindrical coil 100 does not exceed the allowable maximum temperature t_(M) and does not fall below the minimum temperature t_(N) where the refrigerant liquid (pure water) vaporizes.

It is verified that the coreless motors 10 in each of the four cases under the overload condition is capable of being operated continuously with the cylindrical coil 100 being in a completely controlled state and within an appropriate temperature range such as, the maximum temperature t_(c1)=125° C., the minimum temperature t_(c2)=111° C., _(Δ)t=14° C. (T₁), the maximum temperature t_(c1)=128° C., the minimum temperature t_(c2)=113° C., _(Δ)t=15° C. (T₂), the maximum temperature t_(c1)=128° C., the minimum temperature t_(c2)=109° C., _(Δ)t=19° C. (T₃), the maximum temperature t_(c1)=127° C., the minimum temperature t_(c2)=107° C., _(Δ)t=20° C. (T₄), by adjusting the supply amount of the refrigerant liquid (pure water) 80 to the cylindrical coil 100.

Further driving test is performed to reinforce the verifications by the driving tests of the coreless motor 10 in each of the four cases under the overload condition. It is a test where the load torque is set to T₁=0.33 Nm, which is set by the variable load 33 of the electric generator 32, to drive the cureless motor 10 from start-up up to when 300 seconds (5 minutes) passes, then the load torque is set to T₄=0.42 Nm for the next 300 seconds to 600 seconds (another 5 minutes) to drive the cureless motor 10, and the load torque is set to T₁=0.33 Nm again for the next 600 seconds to 720 seconds (further 2 minutes) to drive the cureless motor 10.

FIG. 17 is a test result of the coreless motor 10 being continuously driven for 5 minutes with the torque 5 minutes with the torque T₄, and 2 minutes with the torque T₁ again. As apparent from FIG. 17(a), during the operation test of the cureless motor 10, the temperature t of the cylindrical coil shifts in a range between 109° C. and 126° C., which is the certain temperature range, even under a condition where the load torque is set to T₁=0.33 Nm to drive the coreless motor 10 from start-up up to when 300 minutes (5 minutes) passes, then the load torque is set to T₄=0.42 Nm for next 300 seconds to 600 seconds (another 5 minutes), with repetition of the on/of pulse operation of the refrigerant liquid supply pump 22. FIG. 17(a) is what has excerpted a period from when the cureless motor 10 is started up to when 720 seconds (12 minutes) has passed in a continuous operation test, and we have confirmed that the temperature shift for a period from 720 seconds (12 minutes) onward is almost similar.

The condition for the refrigerant liquid supply pump 22 to operate is when the cooling start (the first read-in) temperature t_(L1)=123° C. is exceeded as in the above cases. At this moment, the refrigerant liquid (pure water) 80 is directly supplied to the cylindrical coil. Then, when the cylindrical coil 100 is cooled by latent heat of vaporization and the temperature falls below the cooling stop (the second read-in) temperature t_(L2)=122° C., the supply of the refrigerant liquid (pure water) 80 is stopped.

FIG. 17(b) is a detail of a part where the load torque is instantaneously changed from T₁=0.33 Nm to T₄=0.42 Nm. Specifically, it is a diagram which has enlarged a temperature waveform of the cylindrical coil 100 of 4 minutes from when 180 seconds (3 minutes) has passed from the start-up up to when 420 seconds (7 minutes) has passed from the start-up. More specifically, since the load torque T₁ is 0.33 Nm from 180 seconds (3 minutes) to 300 seconds (5 minutes), rapid cooling and slow temperature increase can be easily determined from the figure. The first read-in temperature t_(L1) is 123° C., and when the refrigerant liquid 80 is supplied to start cooling at a temperature t exceeding such temperature, the temperature increase is within around 1° C. and then reversed. The second read-in temperature t_(L2) after reverse is 122° C., and even when the supply of the refrigerant 80 is stopped at a temperature t below such temperature, the temperature after decrease further decreases by around 11° C. to 7° C. due to overshoot. Specifically, the maximum temperature t_(c1)=124° C., the minimum temperature t_(c2)=111° C., and _(γ)t=13° C. of the cylindrical coil of 2 minutes from when 180 seconds (3 minutes) has passed from the start-up up to when 300 seconds (5 minutes) has passed from the start-up, with the load torque set to T₁=0.33 Nm, which almost corresponds with the result of FIG. 13, where the maximum temperature t_(c1)=125° C., the minimum temperature t_(c2)=111° C. and _(Δ)t=14° C.

Since the load torque T₄ is 0.42 Nm from 300 seconds (5 minutes) to 420 seconds (7 minutes), rapid cooling and rapid increase of temperature can be easily determined from the figure. The first read-in temperature t_(L1) is 123° C., and when the refrigerant liquid 80 is supplied to start cooling at a temperature t exceeding such temperature, the temperature, increase is within around 4° C. and then reversed. The second read-in temperature t_(L2) after reverse is 122° C., and even when the supply of the refrigerant 80 is stopped at a temperature t below such temperature, the temperature after decrease further decreases by around 13° C. to 10° C. due to overshoot. Specifically, the maximum temperature t_(c1)=125° C., the minimum temperature t_(c2)=109° C., and _(Δ)t=17° C. of the cylindrical coil of 2 minutes from 300 seconds (5 minutes) to 420 seconds (7 minutes), with the load torque set to T₄=0.42 Nm, which almost corresponds with the result of FIG. 16, where the maximum temperature t_(c1)=127° C., the minimum temperature t_(c2)=108° C., and _(Δ)t=19° C. It is thereby confirmed that, even under a load change during operation of the coreless motor 10 where the torque 0.42 Nm is the maximum, it is capable of being appropriately controlled for continuous operation.

FIG. 18 is an experiment result when the cooling start temperature t_(L1) and the cooling stop temperature t_(L2) of the cylindrical coil 100 are changed, with the condition of the torques being identical as shown in FIG. 17, It is a test result of the coreless motor 10 in which, the coreless motor 10 is started, the cooling start temperature is set when the temperature of the cylindrical coil 100 is t_(L1)=110° C., the cooling stop temperature is set when the temperature of the cylindrical coil 100 is t_(L2)=90° C., and continuously driven for 5 minutes with the torque T₁, 5 minutes with the torque T₄, and 2 minutes with the torque T₁ again. In a case where set values of the cooling start temperature t_(L1) and the cooling stop temperature t_(L2) are changed, it is confirmed that the driving system 1 can also operate normally.

The driving tests in the above are performed using pure water of vaporization heat 2257 kJ/kg described in a table of FIG. 19 as the refrigerant liquid. FIG. 19 is a list for melting temperature ° C., boiling temperature ° C., vaporization heat kJ/kg of the refrigerant liquid including pure water 80. Here, a driving test is performed respectively for a case with and without the refrigerant, where a fluorinated liquid, with melting temperature −123° C., boiling temperature 34° C. and vaporization heat 142 kJ/kg, is used as the refrigerant liquid 80, and the coreless motor 10, with the load torque set to T=0.317 Nm, is used.

FIG. 20 represents a respective shift of temperature t of the cylindrical coil 100 in a driving test which uses a fluorinated refrigerant liquid as the refrigerant 80, for a case where the refrigerant liquid supply pump 22 is driven with the refrigerant liquid 80 being supplied to the cylindrical coil 100 and a case without the supply thereof, and the operation condition of the refrigerant liquid supply pump 22 is set such that the cooling start temperature t_(L1)=54° C. (the first read-in) and the cooling stop temperature t_(L2)=52° C. (the second read-in). By this driving test, it is confirmed that, in the operated coreless motor 10, in a case where the fluorinated refrigerant liquid 80 is supplied, the temperature of cylindrical coil 100 may be shifted between 50° C. to 60° C., on the other hand, in a case where the fluorinated refrigerant liquid 80 is not supplied, the temperature of the cylindrical coil 100 exceeds 130° C. in about 10 minutes.

The result of the driving test revealed that the cooling operation to the cylindrical coil 100 by latent heat of vaporization, in which the fluorinated refrigerant liquid 80 is supplied to the cylindrical coil 100 and be vaporized with cylindrical coil 100, is also appropriately controlled by the controlling device 20. It is also verified that, in the coreless motor 10 which uses the refrigerant liquid 80 other than pure water, if the cooling operation to the cylindrical coil 100 can be appropriately controlled, the continuous operation of the coreless motor 10 is possible, and it is confirmed that change of the refrigerant allows change of temperature control range of the coil.

As apparent from the present driving test using the coreless motor 10 of FIG. 8, the present invention is a coreless rotating electrical machine for being operated under a load exceeding a rated load, a driving method thereof, and a driving system including thereof, which at least has the following configurations.

The coreless rotating electrical machine typically has a rotor equipped with a plurality of magnets on an inner surface of a cylindrical mount, or a rotor in which a plurality of magnets are equipped with intervals with respect to each other in a circumferential direction on an outer surface of an inner yoke and/or an inner surface of an outer yoke of a cup-type mount to which the concentric inner yoke and the outer yoke are integrated, and provided with slits, each of which passing through the inner yoke, at positions of the inner yoke corresponding to each of the intervals, or either of them as a constituent requirement, and a stator, which is the other constituent requirement corresponding to the rotor, has an energizable coreless cylindrical coil and consists of a lid-type mount which fixes one of end faces of the cylindrical coil.

As apparent from FIGS. 1, 2 and FIGS. 3 and 4, it further has a channel for supplying a refrigerant liquid to an air space formed by an inner side of the cylindrical coil fixed to the stator and a center part of the rotor and the stator, and has a configuration in which a controlling part or controlling device is activated when driven by a driving part or driving device to adjust a supply amount of the refrigerant to be directly fed to the inner surface of the cylindrical coil via the channel by properly detecting a temperature of the cylindrical coil which generates heat. This is what can be easily understood from FIGS. 5 and 6 which represent the driving system.

It is easily estimated from the variable load 33 in the electric generator 32 of FIG. 7, which is a schematic diagram of a driving test, that the coreless rotating electric machine, the driving method thereof, and the driving system including thereof of the present invention are applicable to various load conditions exceeding a rating. Moreover, the size does not matter as long as a configuration thereof is the same as that of the coreless motor used for the driving test.

The coreless rotating electric machine of FIG. 21 illustrated as a reference diagram is an example in which a configuration of supplying a refrigerant liquid is arranged in a second air space, instead of a first air space shown in FIGS. 3 and 4 which is the position where the refrigerant liquid is supplied. Also in this example, the refrigerant liquid fed to the second air space reaches the cylindrical coil, which generates heat, and vaporized, and the cooling of the cylindrical coil by the latent heat of vaporization is fully possible, and thus, we consider that it may be the coreless rotating electrical machine for being operated under the load exceeding the rating. However, the driving test of the coreless motor based on such configuration has not been performed.

Although the present invention has been described for preferable embodiments, those skilled in the art may understand that various modifications may be made and elements may be replaced with equivalents without departing the scope of the present invention. Therefore, the present invention should not be limited to specific embodiments disclosed as the best mode of embodiments considered for implementing the present invention, and it Although the present invention has been described for preferable embodiments, those skilled in the art may understand that various modifications may be made and elements may be replaced with equivalents without departing the scope of the present invention. Therefore, the present invention should not be limited to specific embodiments disclosed as the best mode of embodiments considered for implementing the present invention, and the present invention encompasses all embodiments which belong to claims.

REFERENCE SIGNS LEST

-   1: Driving system -   2: Stator -   3: Rotor -   4: Magnet -   8: Channel for supplying refrigerant liquid -   10: Coreless rotating electrical machine or coreless motor -   20: Controlling part or controlling device -   21: Coil temperature detecting sensor -   22: Pump -   23: Controller -   24: Electromagnetic valve -   25: Temperature and voltage recording device -   26: Refrigerant liquid flow volume varying device -   30: Driving part or driving device -   31: Power meter -   32: Electric generator -   33: Variable load -   34: Torque sensor -   35: Torque meter -   40: Air space or first air space including air gap -   41: Gap between respective magnets -   50: Second air space -   60: Third air space -   80: Refrigerant liquid or liquid phase -   800: Gas phase of refrigerant liquid -   81: Refrigerant liquid container -   82: Circulating means or circulating and conveying pipe -   100: Cylindrical coil -   101: One of end faces of cylindrical coil -   102: The other end face of cylindrical coil -   110: Inner periphery side of cylindrical coil -   120: Outer periphery side of cylindrical coil -   200: Lid-type mount included in stator 2 -   240: Center part of lid-type mount -   300: Cylindrical mount included in rotor 3 -   310: Inner surface of cylindrical mount -   340: Center part of cylindrical mount -   400: Cup-type mount included in rotor 3 -   401: One of end faces of cup-type mount -   410: Bottom part of cup-type mount -   420: Inner yoke included in cup-type mount 400 -   421: Inside of inner yoke 420 -   422: Outer surface of inner yoke -   423: Slits which pass through inner yoke 420 -   430: Outer yoke included in cup-type mount 400 -   431: Inner surface of outer yoke -   1000: Drive shaft 

The invention claimed is:
 1. A coreless rotating electrical machine to be operated continuously under a load exceeding a rating defined for a condition without cooling, comprising: a stator including an energizable coreless cylindrical coil; a lid-type mount which fixes an end face of the cylindrical coil; and a rotor including a cup-type mount opposingly and rotatably positioned with respect to the lid-type mount, wherein: an air gap is formed between the lid-type mount and the cup-type mount, the cup-type mount is equipped with a plurality of magnets, wherein: an outer surface of each of the magnets is faced to an inner surface of the cylindrical coil within the air gap, an inner surface of each of the magnets is faced to an outer surface of the cylindrical coil within the air gap, or an outer surface of each magnet of a first group of the magnets is faced to an inner surface of the cylindrical coil within the air gap and an inner surface of each magnet of a second group of the magnets is faced to an outer surface of the cylindrical coil within the air gap, the lid-type mount is equipped with a channel for supplying a refrigerant liquid to the air gap, and a controlling part which controls supply of the refrigerant liquid and a driving part which drives the rotor are equipped therewith, wherein, when the driving part is activated and the coreless rotating electrical machine is operated continuously under the load exceeding the rating defined for the condition without cooling, the controlling part is activated to adjust the supply of the refrigerant liquid by repeating a first operation of supplying the refrigerant liquid into the air gap to prevent a temperature of the cylindrical coil exceeding an allowable maximum temperature for a continuous operation, allowing the cylindrical coil, which generates heat, to vaporize the refrigerant liquid to cool itself by latent heat of vaporization of the refrigerant liquid, and a second operation to stop the supplying of the refrigerant liquid to heat the cylindrical coil to prevent the temperature of the cylindrical coil falling below a minimum temperature where the refrigerant liquid vaporizes, so as to maintain the temperature of the cylindrical coil in a range between the allowable maximum temperature and the minimum temperature, which enables the coreless rotating electrical machine to be operated continuously under the load exceeding the rating defined for a condition without cooling.
 2. The coreless rotating electrical machine as defined in claim 1, wherein the refrigerant liquid is water, and the minimum temperature is 100° C. and the allowable maximum temperature is 125° C.
 3. The coreless rotating electrical machine as defined in claim 1, wherein the controlling part comprises a coil temperature detecting sensor for detecting the temperature of the cylindrical coil, a pump for supplying the refrigerant liquid into the air gap, and a controller for adjusting the supply of the refrigerant liquid with on/off commands to the pump in coordination with the coil temperature detecting sensor.
 4. The coreless rotating electrical machine as defined in claim 3, further equipped with a refrigerant liquid container which is in communication with the channel.
 5. The coreless rotating electrical machine as defined in claim 4, wherein the lid-type mount is further equipped with a circulating means which communicates between the refrigerant liquid container and the air gap.
 6. The coreless rotating electrical machine as defined in claim 5, wherein the controlling part collects the refrigerant liquid in a gas phase into the refrigerant liquid container in a liquid phase thereof by the circulating means.
 7. The coreless rotating electrical machine as defined in claim 1, further equipped with a refrigerant liquid container which is in communication with the channel, wherein the controlling part comprises a coil temperature detecting sensor for detecting the temperature of the cylindrical coil, an electromagnetic valve for supplying the refrigerant liquid from the refrigerant liquid container arranged at a position higher than the cylindrical coil into the air gap, and a controller for adjusting the supply of the refrigerant liquid with open/close commands to the electromagnetic valve in coordination with the coil temperature detecting sensor.
 8. The coreless rotating electrical machine as defined in claim 7, wherein the lid-type mount is further equipped with a circulating means which communicates between the refrigerant liquid container and the air gap.
 9. The coreless rotating electrical machine as defined in claim 8, wherein the controlling part collects the refrigerant liquid in a gas phase into the refrigerant liquid container in a liquid phase thereof by the circulating means.
 10. The coreless rotating electrical machine as defined in claim 1, wherein the rotor further includes a drive shaft fixed to a center part of the cup-type mount and rotatably coupled to a center part of the lid-type mount.
 11. The coreless rotating electrical machine as defined in claim 1, wherein the cylindrical coil is formed from a laminate of electrically conductive metal sheets having linear parts being spaced in an axial direction covered with insulating layers formed to a cylindrical form.
 12. The coreless rotating electrical machine as defined in claim 1, wherein the cylindrical coil is formed from a linear conductor covered with an insulating layer formed to a cylindrical form.
 13. A driving method of a coreless rotating electrical machine for being operated continuously under a load exceeding a rating defined for a condition without cooling, the coreless rotating electrical machine comprising a stator including an energizable coreless cylindrical coil, a lid-type mount which fixes an end face of the cylindrical coil, and a rotor including a cup-type mount opposingly and rotatably positioned with respect to the lid-type mount, wherein: an air gap is formed between the lid-type mount and the cup-type mount, the cup-type mount is equipped with a plurality of magnets, wherein: an outer surface of each of the magnets is faced to an inner surface of the cylindrical coil within the air gap, an inner surface of each of the magnets is faced to an outer surface of the cylindrical coil within the air gap, or an outer surface of each magnet of a first group of the magnets is faced to an inner surface of the cylindrical coil within the air gap and an inner surface of each magnet of a second group of the magnets is faced to an outer surface of the cylindrical coil within the air gap, the lid-type mount is equipped with a channel for supplying a refrigerant liquid to the air gap, and a controlling part which controls supply of the refrigerant liquid and a driving part which drives the rotor are equipped therewith, wherein the driving method includes: a step of activating the driving part and operating the coreless rotating electrical machine continuously under the load exceeding the rating defined for a condition without cooling; and a step of activating the controlling part to adjust the supply of the refrigerant liquid by repeating a first operation of supplying the refrigerant liquid into the air gap to prevent a temperature of the cylindrical coil exceeding an allowable maximum temperature for a continuous operation, allowing the cylindrical coil, which generates heat, to vaporize the refrigerant liquid to cool itself by latent heat of vaporization of the refrigerant liquid, and a second operation to stop the supplying of the refrigerant liquid to heat the cylindrical coil to prevent the temperature of the cylindrical coil falling below a minimum temperature where the refrigerant liquid vaporizes, so as to maintain the temperature of the cylindrical coil in a range between the allowable maximum temperature and the minimum temperature, which enables the coreless rotating electrical machine to be operated continuously under the load exceeding the rating defined for a condition without cooling.
 14. The driving method as defined in claim 13, wherein the refrigerant liquid is water, and the minimum temperature is 100° C. and the allowable maximum temperature is 125° C.
 15. The driving method as defined in claim 13, wherein the controlling part comprises a coil temperature detecting sensor, a pump for supplying the refrigerant liquid into the air gap, and a controller for adjusting the supply of the refrigerant liquid with on/off commands to the pump, the driving method further includes a step of activating the coil temperature detecting sensor to detect the temperature of the cylindrical coil, and adjusting the supply of the refrigerant liquid so as to maintain the temperature of the cylindrical coil in a range between the allowable maximum temperature and the minimum temperature includes that the controller commands the pump to be on/off based on a detected temperature of the cylindrical coil.
 16. The driving method as defined in claim 15, wherein the coreless rotating electrical machine is further equipped with a refrigerant liquid container which is in communication with the channel.
 17. The driving method as defined in claim 16, wherein the lid-type mount is further equipped with a circulating means which communicates between the refrigerant liquid container and the air gap.
 18. The driving method as defined in claim 17, further including a step of the controlling part activating the circulating means to collect the refrigerant liquid in a gas phase into the refrigerant liquid container in a liquid phase thereof.
 19. The driving method as defined in claim 13, wherein the coreless rotating electrical machine is further equipped with a refrigerant liquid container which is in communication with the channel, the controlling part comprises a coil temperature detecting sensor for detecting the temperature of the cylindrical coil, an electromagnetic valve for supplying the refrigerant liquid from the refrigerant liquid container arranged at a position higher than the cylindrical coil into the air gap, and a controller for adjusting the supply of the refrigerant liquid with open/close commands to the electromagnetic valve in coordination with the coil temperature detecting sensor, the driving method further comprises a step of activating the coil temperature detecting sensor to detect a temperature of the cylindrical coil, and adjusting the supply of the refrigerant liquid so as to maintain the temperature of the cylindrical coil in a range between the allowable maximum temperature and the minimum temperature includes that the controller operates the electromagnetic valve based on a detected temperature of the cylindrical coil.
 20. The driving method as defined in claim 19, wherein the lid-type mount is further equipped with a circulating means which communicates between the refrigerant liquid container and the air gap.
 21. The driving method as defined in claim 20, further including a step of the controlling part activating the circulating means to collect the refrigerant liquid in a gas phase into the refrigerant liquid container in a liquid phase thereof.
 22. The driving method as defined in claim 13, wherein the rotor further includes a drive shaft fixed to a center part of the cup-type mount and rotatably coupled to a center part of the lid-type mount.
 23. The driving method as defined in claim 13, wherein the cylindrical coil is formed from a laminate of electrically conductive metal sheets having linear parts being spaced in a longitudinal direction covered with insulating layers formed to a cylindrical form.
 24. The driving method as defined in claim 13, wherein the cylindrical coil is formed from a linear conductor covered with an insulating layer formed to a cylindrical form. 